Covering material



Nov. 22, 1938. c. E. RAHR COVERING MATERIAL Filed April 15, 1935ENVENTOR (Ms m? 4. Km.

Patented Nov. 22, 1938 PATENT orricr;

COVERING MATERIAI) Chester E. Rahr, New York, N. Y., assignor toCertain-Teed Products Corporation, New York, N. Y., a corporation ofMaryland Application April 15, 1935, Serial No. 16,289

Claims.

such as asphalt, and forming the' asphalt coatin in such a way that thethickness thereof upon the part of the element tobe exposed in anoverlapping arrangement of such elements is greater and tapers toward athinner layer of the coating upon the part to be overlapped by anotherelement. It has also been proposed inthe past to produce a thick buttshingle by applying over the usual granular surfacing adhering to thenormal coat upon a fabric base, especially upon the portion to beexposedthereof, a second coating of adhesive to which also a secondlayer of granular surfacing material adheres. This has been accomplishedin some cases by dipping the shingle in a'bath of the adhesive material,for example, asphalt, to apply the second coating and subsequentlycovering this coating with a second surfacing of granular material.

The present invention has for its purpose producing a covering elementof the type referred to by applying a second coating over granularmaterial bound upon the base by a first coating but accomplishes thispurpose in a manner different from that heretofore proposed andproduces-a covering element which has not heretofore been produced; Thecovering element of the invention of the element to be exposed and makesit possible to-ut-ilize methods of manufacture by which maybe effected,savings in the cost of manufacture as well as in the cost of thematerials used at to produce a given weight of the covering eleof theoverlapped part with respect to that part ment, particularly upon theportion thereof to be 7 exposed.

The invention comprises the operations of coating the base fabric and ofapplying thereto the granular surfacing material while controlling thethickness of the part of the element to be overlapped with respect tothat which is to be exposed. In order to carry out these operations theinvention contemplates applying to 'a base fabric an adhesive coatingwith a given thickness upon that part of the base which is to be exposedbut limiting to less than said thickness the thickness of v the coatingupon that part of the base fabric which is to be overlapped. In thepreferred embodiment of the invention, upon the thicker portion ofthecoating is applied a layer of granular material, such as slate, orother mineral granules of a given size. When said portion of the coatingis of normal thickness these granules may be of the size normally usedin the manufacture of elements of the type to which the inventionrelates, and said layer of granules may be of normal thickness. Uponthat part of the element which is to be overlapped, and which carriesthereon the coating of less thickness, however, preferably is applied alayer of fine granular material of such grain size'as to be capable ofadhering to saidthinner coating. The coarse or large granules do not soreadily adhere to a thin coating as do small or fine granules but 'doreadily adhere to the thicker coating and may be pressed thereinto. Thusit will be understood not onlyv that the difference in thickness,between the part of the element which is to be exposed with respect tothat which is to be overlapped, is ereated by the difference in thethicknessof the coating but that this difference is eccentuated by thedifference in thickness of the granular layers of surfacing because ofthe difference inthe grain upon a fabric base heretofore have beenutilized, a

the invention goes beyond this step by again applying to the wholesurface of the covering element a coating of the adhesive material. Thethickness of this second coating also is made greater for that part ofthe element to be exposed and is reduced for that part of the elementwhich is to be overlapped. Suflicient coating. however, is used in thethinner portions of both coatings to'bind fine granules thereto. Thusthere is secured an added accentuation of the difference between thethickness of the part of the element which is to be exposed withrelation to that to be overlapped. The invention contemplates, how- 56 emannerof the invention;

ever, the further step and feature of applying to preferably of a sizenormally used in surfacing roofing materials, whereas, upon that part ofthe element which is to be overlapped there is applied fine granularmaterial and of a grain size capable of adhering to said second coatingof reduced thickness. Thus there is obtained a still greateraccentuation of the difference between the thickness of the part of theelement which is to be exposed and that part thereof which is to beoverlappedin an assembly ofelements in a roofing structure.

In the embodiment above described the invention provides that the partof the element which is to be exposed in an assembly of elements in astructure has a uniform thickness and the part to be overlapped likewisehas a reduced but uniform thickness creating what may be called a stepor shoulder between these two portions. The invention, however, is notlimited to such an embodiment and the coating. may be applied indifferent thicknesses in more than two portions of the area of theelement. The thickness of the coatings. upon an intermediate area, forexample, may be intermediate thatupon the exposed-part and that upon thepart to be overlapped. The size of the granules upon the intermediatearea may be correspondingly intermediate the sizes of the granules uponthe adjacent areas. Thus will be secured a more gradual reduction of thethickness from the butt end to the opposite end of the element. In theultimate case this reduction and the corresponding gradation of thegranules may be accomplished by forming the asphalt coatings with apress roll or other forming device to taper this thickness from the buttto the overlapped edge of the element. in grain size from larger tosmaller in the direction from the thicker portion of the coating to thethinner portion thereof may be applied to the respective coatings. Thisreduction and gradation within practical limits may be repeated inapplying several coatings and layers of surfacing material whilemaintaining the difference in thickness of the coating in the successiveportions of the element and, as well, the difference in the grain sizeof the granular materials applied thereto.

The invention will be more fully understood from the description of thedrawing in which Figure 1 shows in plan a sheet. formed in the Figure 2shows a cross-section on line 2-2 of Figure 1;

Figure 3 shows in plan a modified form of a sheet utilizing theinvention;

Figure 4 is a section on line 44 of Figure 3;

Figure 5 is an enlarged cross-section of a portion of the sheet shown inFigure 1; and t Figure 6 shows a, modification of the invenion. 1

In Figures 1 and 2 the sheet I is formed with the marginal portions 3thereof of greater thickness than the portions 4 thereof inwardly ofthese-margins. The sheet is also formed with a central portion 5 ofgreater thickness. In the form of sheet shown in Figures 1 and 2, inwhich the portions 3 and 5 represent bands or areas lengthwise of thesheet which have a greater thickness than the areas lying therebetween,the sheet may be out upon the dotted lines 6 and 1 Surfacings ofgranular material graded to sever the sheet into strips, each having athick portion 3 and a thinner portion formed from the thin portion 4 ofthe sheet. The width transversely of the sheet of the bands 3' may bethat of the part to be exposed of a covering element, and the widthbetween the severing lines 6 and the shoulders or steps formed by theportions 3 and 5 with respect to the portions 4 may be that part of theelement which is to be overlapped in an assembly of elements upon a roofor other structure. The width of the band 5 may be made twice that ofthe bands 3 in order that by the severing cut I similar elements tothose produced on the marginal portion of the sheet will be produced ateither side of the central cut I. To produce covering elements ofsuitable length, transverse cuts 9 may be made across the sheet andacross the several strips formed by the severing cuts 6 and 1.

In Figures 3 and 4 are shown in plan and section a sheet having thickportions 3 and thin portions 4, the sheet being severed on lines 8 atthe shoulder between the portions 3 and 4. In some cases the line ofseverance may be slightly removed from the edgeof the portion 3 and maycut through only the portion 4. Thus the cutting may be eifected througha thin portion only of the sheet and the wear upon the cutting knivesmay thus be reduced while substantially obtaining the form of elementembodying the features of theinvention. In order to form the thick andthin portions 3 and 4 as shown in section in Figure 5 illustrating thedetail of the construction of the sheet embodying the invention, upon abase I0, such as a roofing felt saturated with a bituminous saturant,may be applied a coating I 2 of asphalt of the character utilized inroofing to bind granular surfacing material such as slate upon the basefelt. The coating l2 has a portion M of normal thickness or of suchthickness as to bind upon the base l granular material l of a normal orgiven grain size. The coating 12 also has a portion iii of lessthickness than the portion I4 but of such thickness as to bind uponthebase I ll granular material ll of a grain size less than that of thegranular material l5.

Upon the granular surfacing material i5 is applied a portion I 8 of asecond coating of adhesive binder, which may be of asphalt of the sameor similar quality as that of the coating i2. This second coating alsohas a portion I 9 extending over the granular material [1, the portionI! being of less thickness than the portion [8 applied upon the granulesl5. This coating serves in its respective portions l8 and I9 to bind thegranules 2| and 22 respectively to the granules i5 and I1- and to therespective portions l4 and I6 of the coating I2. The granules 2i may beof similar size to the granules i 5 and the granules 22 may be ofsimilar size to the granules l1. 7

It will be clear that the portion 3 is built up I of a normal coatingbinding upon the base I 0 granules of normal size and having boundthereto and to the granules IS a coating of similar thickness to whichadheres a second layer of granules of normal size. The portion of thesheet upon which is applied the thin coating l6, however, is built up ofthis thin coating l6 and small granules bound thereto upon which a second thin coating is applied to which adheres a second layer of smallgranules. Thus the thin portion 4 of the sheet is formed with materialsof reduced sizes or thickness while the portion 3 is formed withmaterials of normal size or of a size larger than that of the respectivematerials upon the portion 4.

The thickness of the coatings upon the respective portions may be mademerely sufficient to bind upon the base of the structure thus formed thegranular material of the sizes being used. The size of these granulesand the thickness of the coatings, however, may be made such as toprovide not only the desired, degree of weatherproofing but also tobuild up the desired thickness of the butt and of the exposed part ofthe element. In the portion 4 of the sheet which is to be overlapped byelements in a superimposed course in a roof structure and therefore isnot exposed to the weather, the coating need be only of suflicientthickness to hold upon the base granular material of fine grain size,such as fine slate or sand, in order that this fine granularmaterial andthe coating to which it adheres may form a suitable base to bind uponthemselves the second coating and the fine granular material adheringthereto.

In Figure 5 the line it represents a line of severance, as in Figures 1and 2, to cut apart strips having a thick portion 3 of a width toprovide the part'to be exposed and a thin portion d. .The

i it

Width of the portion t, as illustratedin Figure 5, may be double that ofthepart to be overlapped by a superimposed strip and preferably is ofsufficient width to aflord this overlap plus the usual headlapf providedin roof structures of this type.

Figure 6 represents a modification of the invention in which, upon abase sheet it, is applied a coating it, which coating is formed by meansof a forming roller or other suitable means with a tapered section sothat adjacent the edges of the sheet and at the center thereof theportions f b. are'of less thickness than the portions 21!, which areintermediate these thin portions 25. If the sheet is cut longitudinallythereof as upon lines fill and it the strips thereby produced will havethe coating if thereof of tapering section in the direction from onelongitudinal edge of the strip to the other.

If upon the coating l2, and preferably before the cutting operation justreferred to, is applied a layer of surfacing material it having upon theportions ft'relatively fine grain size and upon the portions 21!relatively coarse grain size, and if intermediate between these portionsthe granular material is graded in size between that of the small grainsand that of the large grains, the tapering section of the strip orelement thus produced may be maintained and accentuated; Moreover, ifupon the surfacing layer 30 is applied a second coating 32 tapered inthe same manner and in the same direction as coating [If and, further,if upon this coating 32 is applied a second layer 36 of granularsurfacing material I graded in grain size in the same manner as thesurfacing layer 3u-there may be produced a strip or element of greaterthickness adjacent the lines 28 than the thickness at the edges of thesheet Ill and adjacent the line 29. When the sheet Ill is severed uponthe lines 28 and 29 the longitudinal strips thus produced may be cutinto suitable lengths to produce covering elements which wil have athick butt provided by that portion which is adjacent the lines ofcutting 28 and tapering to a thin portion which may be overlapped by thethick butt portion of a superimposed element in the usual manner oflaying shingles or similar covering elements.

.coatings of reduced thickness upon the base in the superimposedrelations as shown. It is a feature of the invention that thedifferences in thickness of the exposed and overlapped parts of theelements produced is accentuated by the cooperation of the thickgranules with the thick coatings in comparison with the granules ofsmall size and their correspondingly thin coatings.

The thickness of one coating in itsportions of greater and lessthickness may respectively be the same as those of the superimposed orunderlying coating or these respective and corresponding portions may be'of different thickness. One coating may also have its thicker portionof the same thickness as the superimposed or underlying coating and mayhave its thinner portion of greater or less thickness than that of thesuperimposed or underlying coating. Similarly, the thickness of the twocoatings in their thinner portions may be the same and the thickness ofthe thicker portions may be greater or less in the two coatings.Moreover, in that embodiment of the invention in which coatings oftapering thickness are utilized, the tapering need not be uniform andthe portion of the superimposed coating at any point upon the elementmay be greater or less than that of the underlying coating. In suchmodifications of the invention, however, that feature is maintainedwhich utiliaes a granular material which is smaller upon the thinnerpora mathematical or proportionate relationship is not intended but theterm is used in its broader sense to indicate that the thinner portionsof one coating are superimposed upon the thinner portions of, anunderlying coating while the thicker porticns of the first coating aresuperimposed upon the thicker portions of the underlying coating.

Having thus described my invention I claim:

1. Process of producing a covering material which comprises applying toa base material an adhesive coating, said coating being applied'upon a.portion of the surface of said base with a thickness sufficient to bindupon said base a granular material of given grain size and being appliedupon another portion of the surface of said base with less thickness butsufiicient to bind upon said base a granular material of a grain sizeless than that bound upon said first area, applying to becomesaccentuated relative to the thin part of the cover. I

2. Process of producing a covering material bill which comprisesapplying to a base material an adhesive coating, said coating beingapplied upon 7 applying to said portions of said surface a coatinghaving upon the respective portions thicknesses. corresponding to thoseof the first coating, and applying to said second coating granularsurfacing material of grain sizes upon the respective portions of thesurfacecorresponding to the grain sizes of the first granular surfacingmaterial, whereby the thickness of the thick part of the coveringbecomes accentuated relative to the thin part of the cover.

3. Process of producing a covering material which comprises applying toa base material an adhesive coating, said coating being applied upon aportion of the surface of said base with a thickness sufiicient to bindupon said base a granular material of given grain size and being appliedupon another portion of the surface of said base with less thickness butsuflicient to bind upon said base a granular material of a grain sizeless than that bound upon said first area, pplying to the portion of.said coating having the greater thickness granular surfacing materialof said given grain size, applying to the portion of said coating oflesser thickness granular surfacing material of a smaller grain sizethan that upon said portion of greater thickness, and repeating thesteps of applying a coating with portions having greater or lessthickness and of surfacing said coating with granular materials of thegivenand smallergrain size respectively upon said portions havinggreater and less thickness of said first coating.

4. A covering material comprising a base pro viding a surface ofsubstantial extent, a coating of adhesive upon said base, said coatingupon a portion of said base being of a thickness sufiicient to bind uponthe base a granular material of given grain size and upon anotherportion of said base being of less thickness but suflicient to bind uponsaid base a granular material of a grain size less than said given grainsize, granular surfacing material of said given grain size bound uponsaid portion of the coating of greater thickness and granular surfacingmaterial of less grain size bound upon said portion of the coating ofless thickness, and a second coating of adhesive adhering to said firstsurfacing and coating and respectively of greater thickness and lessthickness upon the portions of the first coating having greater and lessthickness, said second coating binding to itself and to the coveringmaterial a surfacing of granular material have ing greater and lessgrain size respectively upon the portions of greater and less grain sizebound upon said first coating, said thick portions of the coatings andthe large grain surfacings building up an accentuated thickness of thecovering relative to that provided by the thin portions of the coatingsand the small grain surfacings.

5. A roofing element having bound upon a fabric base by a coating ofweather-resisting adhesive a layer of granular surfacing material andhaving a second layer of granular surfacing material bound upon saidfirst surfacing material and upon said first coating by a secondadhesive coating, the thickness of each coating upon the part of theelement to be exposed to the weather being greater than that upon thepart of the element to be overlapped in an assembly of said elements,the grain size of the granular material upon each coating beingrespectively larger and smaller upon the parts of the element to beexposed andto be overlapped, said thick coatings and the granularmaterial of larger grain size upon the part of the element to be exposedbuilding up an accentuated thickness relative to the thickness providedby the thin coatings and granular material of smaller grain size uponthe part of the element to be overlapped.

6. A covering material comprising a base providing a surface ofsubstantial extent, a coating of adhesive upon said surface of said basehaving a thickness tapering from that upon one part thereof to that uponanother part of said surface, granular material adhering to said coatingand covering said tapering portion of said coating, said granularmaterial upon said tapering portion being graded in grain size from asmaller grain size upon the part of the coating having a less thicknessto a larger grain size upon the part having a greater thickness, theparts of the coatings of greater thickness and the large grain materialthereon building up an accentuated thickness of the covering relative tothe parts of the covering having thereon the coating of less thicknessand the small grain material thereon.

7.'A covering material comprising a base pro: viding a surface ofsubstantial extent, a coating of adhesive upon said base, said coatingupon a portion of said base being of a thickness sufiicient to bind uponthe base a granular material of given grain size and upon anotherportion of said base being of less thickness but sufficient to bind uponsaid base a granular material of a grain size less than said given grainsize, granular surfacing material of said given grain size bound uponsaid portion of the coating of greater thickness and granular surfacingmaterial of less grain size bound upon said portion of the coating ofless thickness, and a second coating of adhesive adhering to said firstsurfacing and coating and respectively of greater thickness and lessthickness upon the portions of the first coating having greater and lessthickness, said thick portions of thecoatings and said granular materialof given grain size building up an accentuated thickness of the coveringrelative to that provided by the thin portions of the coatings and thegranular material of less grain size.

8. Process of producing a covering material which comprises applying toa base material an adhesive coating, said coating being applied upon aportion of the surface of said base with a given thickness and beingapplied upon an adjacent portion of the surface of said base with lessthickness and so as to be demarked from said portion of given thickness,applying to said portions of the surface of given and less thicknessgranular material respectively of larger and smaller grain size,applying to said surface so as to maintain said demarcation of saidportions a coating having a greater and less thickness upon the portionsof said first coating which are of given and of less thickness, andcutting throughsaid base and the applied materials adjacent the line ofdemarcation between said portions of the surface to sever a coveringmaterial having apart of greater thickness and a part of less thicknessadjacent thereto, whereby a covering having an accentuated thickness inthe thick portions is secured.

9. Process of producing a covering material which comprises applying toa base material an adhesive coating, said coating being applied upon aportion of the surface of said base with a given thickness and beingapplied upon an adjacent portion of the surface of said base with lessthickness and so as to be demarked from said portion of given thickness,applying to said portions of the surface of given and less thicknessgranular material respectively of larger and smaller grain size,applying to said surface so as to maintain said demarcation of saidportions a coating having a greater and less thickness upon the portionsof said first coating which are of given thickness and of lessthickness, applying to said second coating granular surfacing materialof grain sizes larger and smaller respectively upon the portions ofgreater and less thickness, and cutting through said base and theapplied materials adjacent the line of demarcation between said portionsof the surface to sever a covering material having a part of greaterthickness and a part of less thickness adjacent thereto, whereby acovering having surface; granular material adhering to said coat-- ingand covering said tapering portion of said coating, said granularmaterial upon said tapering portion being graded in grain size from asmaller grain size upon the part of the coating having a less thicknessto a larger grain size upon the part having a greater thickness, asecond coating of adhesive superimposed upon said granular material andhaving the thickness greater upon said thick portion of the firstcoating and less upon'said thin portion of the first coating, the partsof the coatings of greater thickness and the larger grain materialbuilding up an accentuated thickness of the covering relative to theparts of the covering having thereon the coatings of less thickness andthe small grain material.

CHESTER E. RAHR.

